Dynamic modeling of synchronous machines in developing tools for automotive applications

In the last years, the electrification process in the automotive sector is in continuous and fast growth. This has led to the needing of reliable and accurate tools for testing and validating electrical powertrains. Some virtualization techniques are used in order to reduce costs and time. Among the virtualization methods, one of the most used is the Hardware in the Loop (HiL) simulation. This technique consists of a real-time simulation where one or more elements of the system are tested without the needing of the connections to the other hardware. An example could be the calibration of a motor control unit without it being connected to the inverter and/or the electric motor. In this thesis, the virtualization of an electric machine is carried out in order to use it in a HiL simulation. The simulation hardware consists of the dSPACE rapid prototyping board and uses the library “XSG Electric Library” provided by dSPACE for developing the model. This work born from a collaboration between Politecnico di Torino, Powertech Engineering S.r.l., an engineering consulting company specialized in the field of 3d-cfd, 1d and xil simulation, applied to both conventional and electrified. The focus of the thesis is on an Internal Permanent Magnets (IPM) synchronous motor. The aim is to compare the dSPACE model of the above-mentioned machine with the one built on Simulink following the well-known characteristic equations. The models of this motor are realized in rotatory reference frame (dq). From FEM simulations, the necessary parameters of the machine as flux maps, inductance maps, iron equivalent resistance and so on are obtained. These values are necessary to validate the model and to conduct an accurate power analysis of the system. To do that, both models are modified with the addition of the iron losses. For completeness, also a Voltage Source Inverter (mean value and PWM) with losses is modelled on Simulink, in order to take it into account in the power analysis as well. Finally, for the validation of the dSPACE motor model, thirteen operating points obtained with FEM simulation, are tested in steady-state condition